Hummer H1 (2006+). Manual - part 285

10-2 Body

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Side Hood Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-74

Instrument Panel

Center Dash Assembly Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Gauge Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Gauges and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Indicator Lamp Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-19
Instrument Panel Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-16
Right Side Crash Pad Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-18
Switch Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-20
Upper Crash Pad Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-17

Interior Trim

B-Bar Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
Driver’s Compartment Trim Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-35
Inner Kick Panels Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-38
Outer Kick Panel Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Passenger’s Compartment Trim  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-32
Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-31
Station Wagon Rear Compartment Trim   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-37
Tunnel Carpet, Padding and Hardboard Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-40
Interior Trim, Four-Passenger Soft Top  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-97

License Plate Bracket

Front Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94
Rear Bracket Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-94

Lights

Front Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-126
Interior and Exterior Lighting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-116

Backup Light Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-125
Cargo Light  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-122
Courtesy Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-125
Domelight Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-122
Front Turn Signal Light Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-119
Identification Light Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-118
Optional Trouble Light Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-125
Rear Turn Signal Light Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-121
Service Headlight Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-116
Service Headlight Electrical Connector and Grommet Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-127
Side Marker Light Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-118
Side Marker Light Lens and Lamp   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-117
Underhood Light Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-125

Load Barrier and Mounting Brackets 10-30
Mirrors

Lighted Visor Mirror Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-125
Power Mirrors  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-42
Rearview Mirror Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-43

Power Windows and Door Locks

Front Door Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-53
Rear Door Harness Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-56

Rear Striker Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-91
Rear Support Bow Bracket, Station Wagon . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-90
Rear Vertical Door

Door Frame and Seal Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-115
Door Handle Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
Door Latch and Latch Rod Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-112

______________________________________________________________________

Body 10-3

Door Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111
Door Stop Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-114
Window Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-111

Removable Load Barrier and Mounting Brackets Replacement (Station Wagon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-30
Rocker Panel Protection Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-93
Seat Belts

Seat Belt Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-25
Seat Belt Retractor Assembly Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-26

Seats

Front Seats . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-27
Reclining Seat Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-28

Soft Top

Mounting Components and Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-98
Soft Top Support/Roll Cage Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-105

Speedometer/Odometer Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-20
Splash Shield (Engine) Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-78
Tailgate   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-106

Chain Brackets Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-106
Chain Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
Hinge Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-109
Tailgate and Seals Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-107

Tire Jack and Optional Triangle Warning Kit Hold-Down Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-96
Visor Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-41
Water Leak Detection and Repair  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-15
Windows

Power Window Regulator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-60
Window Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-64

Windshield

Assembly Maintenance   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
Glass and Weatherstrip Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80
Heated Windshield  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-84
Reservoir and Pump Assembly  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
Washer Hoses Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-88
Washer Nozzle Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  10-87, 10-88
Washer System and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
Windshield Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-80

Windshield Wipers

Wiper Jumper Harness Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-87
Wiper Linkage Replacement   . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
Wiper Motor Assembly Replacement  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85
Wiper Pivot Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Wiper System and Components  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-85

10-4 Body

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GENERAL BODY INFORMATION

The HUMMER H1 body is constructed from high strength T6 aluminum. Welding should not be performed to make body
repairs. Heat generated by welding will reverse the tempering process, causing a reduction in material strength.

The hood and engine access covers are made of fiberglass (sheet molding compound). Cracks, splits or holes may be repaired
with a glass-reinforced plastic laminate.

Solid 0.1875 in. (4.8 mm) diameter aluminum rivets are the primary method of joining body components. Each rivet is
inserted into a hole through two pieces of metal and a second head is formed by manual or pneumatic impacting or by
squeezing the rivet. When making repairs, use blind rivets of the same size or oversize, with the appropriate grip length.

Blind structural aluminum rivets of 0.1875 in. (4.8 mm) diameter are used in applications where there is access from only one
side of the part. Blind rivets are installed using a tool that pulls on the rivet stem causing a bulbed head to form on the back
side of the part. Fastening is complete when stem breaks off. High strength is obtained in blind rivets by mechanically locking
the remaining stem inside the rivet body.

Steel pull-type lock bolt fasteners of 0.1875 in. (4.8 mm) and 0.25 in. (6.4 mm) diameters are used where tension or high-shear
loads exist. Lock bolts are two-piece unthreaded fasteners. One part is a high-strength, steel-headed, bolt-like part with
serrations on its shank. The mating part is a collar which is swagged over the serrations causing the fastener to be locked in
place.

To facilitate body repairs, it is acceptable to replace lock bolt fasteners and rivets with 0.25 in. (6.4 mm) series bolts. Do not
replace lock bolt fasteners with rivets. Standard threaded fasteners should not be used, as these will quickly wear the
aluminum structure. Bolt lengths should be chosen so that the cylinder portion of bolt is bearing on all members being joined.
Bolts are designed as AN4-XX or AN4-C-XX, where XX defines grip length. Tighten all bolts to 71 lb in. (8 N•m).

Fatigue strength of riveted joints and seams is increased by epoxy adhesive application. Epoxy adhesive requires special
material storage and metal preparation along with a low temperature heat cycle for curing. Where possible, extra rivets and
thicker metal gauges should be used instead of adhesives when making repairs. Parts may be difficult to separate, even after
rivets are removed.

BODY INSPECTION AND REPAIR

General Information

Damaged areas should be thoroughly cleaned and inspected to determine the cause and extent of damage. Body parts should be in-
spected for holes, cracks, dents, distortion or breaks. Fasteners should be inspected for breaks, stretching, looseness, cracked heads
or hole elongation. Seams, flanges and joints should be inspected for straightness or local deformation as an indication that fasten-
ers may have been stretched or holes elongated. It is possible for this to happen and fasteners will still appear to be tight in their
holes. In addition, thoroughly inspect adjacent areas to determine if high loads have been transmitted from the damaged area to
other areas. This can result in secondary damage in the form of distorted panels or seams, loosened or sheared fasteners, elongated
fastener holes and/or cracks.

Classi cation

After the extent of damage has been determined, affected parts should be classified into one of the following categories:

• Negligible damage

• Damage repairable by patching

• Damage repairable by insertion

• Damage necessitating replacement of parts

Negligible damage.

Minor dents, nicks, scores, cracks and holes in a body panel which are within or are brought within, reasonable limits by a simple
procedure without extensive rework are considered negligible damage. These defects should be considered more serious if located
in main structural members such as frame rails, A-pillars or floor cross members rather than in body panels such as cowls or rear
wheelhouses. Deep wrinkles of undetermined origin in body panels should not be classed as negligible until the source of the wrin-

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Body 10-5

kles has been investigated and positively identified. Damage other than small dents, holes, nicks and scratches will require repair or
replacement of the part.

• Negligible Cracks. Isolated cracks less than 0.50 in. (1.27 cm) long may be classified as negligible cracks provided they are

stop drilled at each end to stop propagation.

• Negligible Holes. Isolated holes no more than 0.50 in. (1.27 cm) in diameter (after they are made round with smooth edges)

are classified as negligible holes, provided the distance from the edge of the holes to the nearest line of rivets exceeds the di-
ameter of the hole.

• Negligible Dents and Distortion. Small dents and distorted areas may be classed as negligible if they can be repaired by

hammering or bending without causing the material to crack. Heat will not be used for reforming.

Damage repairable by patching.

Non-negligible damage must be repaired or the section must be replaced. Patches can often be applied over damaged body panels,
provided the damaged area is first trimmed to remove sharp edges or notches which could cause the start of new cracks. The patch
must then be sized to overlap the area to allow for attaching rivets.

Damage Repairable by Insertion.

In certain cases, patch repairs may not be desirable because of impracticality or because a flush surface is desired. In this case, the
damaged area must be cut away and replaced with equivalent material inserted flush with adjacent areas and backed up with a dou-
bler.

Damage requiring replacement of parts.

Parts too badly damaged for repair or cases where replacement is easier than repair, fall into this category. Repair of welded assem-
blies such as body mounts are also included. Welded assemblies cannot be rewelded without destroying the strength of the part,
and must be replaced.

Rivet Failure

Signs of rivet failure include tipped heads, looseness and sometimes chipped or cracked paint. If heads are tipped in the same direc-
tion and rivets are loose in consecutive groups, the joint has undergone excessive load. Rivet heads which are tipped in different di-
rections and are not in groups may be improperly installed. With chipped or cracked paint, it may be necessary to remove paint to
check the true condition of rivets. Rivets subjected to critical loads, but showing no distortion should be inspected if failure is sus-
pected. The head should be drilled off and the shank should be carefully punched out. Failure is indicated by notched rivet shanks
and misaligned holes. Flush rivets showing head slippage within the dimple or countersink indicate either sheet bearing or rivet
shear failure and must be removed for replacement. If rivet failure cannot be detected by visual inspection, the joint can be checked
by drilling and punching out several rivets. If rivet shanks are notched, rivets should be replaced with the next larger size rivets. If
rivet holes show elongation due to local failure in tearing of the sheet, the next larger size rivet must be used in replacement. Any
deformation of the sheet around the rivet, tear outs or cracks between rivets usually indicates partially failed or damaged rivets.
Complete repair of the joint will require replacement by the next larger size rivets. Use the next 0.031 in. (0.79 mm) larger diame-
ter rivet to obtain a tight joint when original hole has been enlarged. If original size rivet is installed, the rivet will not be able to
carry its share of the shear load and the joint will not meet its strength requirements.

Lock bolt Fastener Failure

Lock bolts are used to withstand tension loads and high-shear loads. These fasteners are installed in their holes with an interference
fit. No looseness can be permitted. Lock bolts showing evidence of being stretched, broken, loose in their holes, or having heads
that do not set flat against the surface must be replaced. Guidelines used for detecting rivet failures also apply to lock bolts.

Lock bolt Removal

Working from the head side of the lock bolt, if accessible, file a small flat surface on the head, if it is rounded.

Center punch the head.

Using a hardened drill bit slightly smaller than the lock bolt, drill through the head. In cases where the lock bolts are too hard
to be drilled with the available drills, grind the head down using a cutoff wheel or a carbide bit in a die grinder. When using the
grinder method, cut the head down until it is very thin, but do not grind it off completely or touch the body part with grinding
tool.

Use a pin punch to pry off the head or shear it off with a sharp chisel. Ensure the part is adequately supported while performing
this step.

Drive the lock bolt out of its hole with a pin punch. Care must be taken so that the hole or the part is not distorted.

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